Komatsu HM400-2 Dump Truck Operation and Maintenance Manual (CEAM017604)

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Komatsu HM400-2 Dump Truck Index:

INTRODUCTION
- FOREWORD
- SAFETY INFORMATION
  - Safety Labels
- INTRODUCTION
  - Intended Use
- LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
  - Product Identification Number (Pin)/Machine Serial No. Plate
  - EPA Regulations, Engine Serial No. Plate Position
  - Service Meter Position
  - Table to Enter Serial Numbers and Distributor
- TABLE OF CONTENTS
SAFETY
- SAFETY LABELS
- SAFETY AND WARNING DECALS
  - Location of Safety Decals
  - Safety Labels
- GENERAL SAFETY RULES AND PRECAUTIONS
  - General Safety Rules
  - Safety Features
  - Personal Protective Equipment
  - Fire and Explosion Prevention
  - Action if Fire Occurs
  - Fire Extinguisher and First Aid Kit
  - Fire Prevention and Suppression
  - Dust Hazard Precautions
  - Keep Operator’s Cab Clean
  - Unauthorized Modifications
  - Leaving Operator’s Compartment
  - Mounting and Dismounting
  - Crush or Pinch Point Dangers
  - Inside Operator’s Compartment
  - Precautions When Using ROPS
- PRECAUTIONS BEFORE STARTING OPERATIONS
  - Pre-Operational Checks
  - Starting Your Work Operations
  - Work Site Hazards
  - Avoiding Dangerous Situations
  - Working Clearances
  - Operating on Snow or Icy Surfaces
  - Asbestos Hazard Alert
- RULES FOR ROAD TRAVEL
  - Precautions When Traveling
  - When Traveling on Slopes
  - When Dumping a Load
  - Ensure Good Visibility
  - When Traveling in Reverse
  - Parking the Machine
- PRECAUTIONS DURING MAINTENANCE OPERATIONS
  - Warning Tags
  - Equipment Storage
  - Working Under the Machine
  - Using Drop Lamps
  - Keeping the Machine Clean
  - Performing General Maintenance Procedures
  - Running the Engine During Maintenance
  - Proper Tools
  - Engine System High-voltage
  - Welding, Grinding or Cutting
  - When Using Hammer
  - Refueling the Machine
  - Cooling System Precautions
  - Battery Precautions
  - Starting the Machine
  - High Pressure Hoses
  - Safety Handling High-pressure Hoses
  - Precaution for High Fuel Pressure
  - High Temperature Areas
  - Disposal of Waste Materials
  - Accumulator
  - Critical Parts
- HANDLING TIRES
  - Precautions When Storing Tires
- TRANSPORTATION
  - Precautions When Transporting
  - Steps for Transportation
  - Method of Securing Machine
  - Method of Lifting Machine
  - Location of Lifting Points
- TOWING MACHINE
OPERATION
- GENERAL VIEW
  - Machine
  - Controls and Gauges
  - Machine Monitor
- EXPLANATION OF COMPONENTS
  - Machine Monitor
  - Switches
  - Control Levers And Pedals
  - Safety Pin
  - Articulate Lock
  - Location of Fire Extinguisher
  - Dust Indicator
  - Circuit Breaker
  - Fuses
  - AM/FM Radio-cassette Stereo
- AIR CONDITIONER
  - General Locations on Control Panel
  - Method of Operation
- OPERATION
  - Check Before Starting Engine
  - Checks Before Starting
  - Adjustments Before Operation
  - Operations, Checks Before Starting
  - Starting the Engine
  - Operations, Checks After Starting Engine
  - Stopping Engine
  - Moving the Machine
  - Steering the Machine
  - Loading Operations
  - Handling Tailgate
  - Dump Operations
  - Cab Tilt Operation
  - Permissible Water Depth
  - Parking Machine
  - Checks After Completion of Work
  - Handling of KOMTRAX
  - Handling Tires
  - Determining and Maintaining Travel Road
- TRANSPORTATION
  - Precautions When Transporting
  - Steps for Transportation
  - Method of Securing Machine
  - Method of Lifting Machine
- COLD WEATHER OPERATION
  - Precautions for Low Temperature
  - Precautions After Completion of Work
  - After Cold Weather
- LONG-TERM STORAGE
  - Before Storage
  - During Storage
  - After Storage
- TROUBLESHOOTING
  - After Running Out of Fuel
  - If Transmission has Trouble
  - Method of Lowering Dump Body in Emergency
  - Method of Towing Machine
  - When Parking Brake has Been Actuated in Emergency
  - Method of Releasing Parking Brake
  - When Final Drive, Differential, Transmission, Transfer Have Broken Down
- PRECAUTIONS FOR CHARGING BATTERY
  - Charging Battery when Mounted on Machine
  - If Battery is Discharged
  - Removal and Installation of Battery
  - Starting Engine with Booster Cable
- OTHER TROUBLE
  - Electrical System
  - Chassis
  - If Accelerator Pedal has Failed
  - Engine
- ACTION CODE
MAINTENANCE
- GUIDES TO MAINTENANCE
  - Check Service Meter
  - Komatsu Genuine Replacement Parts
  - Komatsu Genuine Oils
  - Always Use Clean Washer Fluid
  - Always Use Clean Oil and Grease
  - Checking Foreign Materials in Drained Oil and on Filters
  - Fueling
  - Welding Instructions
  - Do Not Drop Things Inside Machine:
  - Dusty Work Sites
  - Avoid Mixing Oil
  - Locking Inspection Covers
  - Bleeding Air From Hydraulic Circuit
  - Precautions When Installing Hydraulic Hoses
  - Checks After Inspection and Maintenance
- OUTLINES OF SERVICE
  - Handling Oil, Fuel, Coolant, and Performing Oil Clinic
  - Outline of Electric System
- WEAR PARTS LIST
- RECOMMENDED FUEL, COOLANT, AND LUBRICANT
- USE OF FUEL, COOLANT AND LUBRICANTS
  - Selection According to Ambient Temperature
  - Recommended Brands, Recommended Quality for Products other than Komatsu Genuine Oil
- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
  - Torque List
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
  - Safety Critical Parts
- REGULAR SCHEDULED MAINTENANCE
  - Maintenance Schedule Chart
  - Initial 250 Hours Service (Only After the First 250 Hours)
  - When Required
  - Check Before Starting
  - Every 50 Hours Service
  - Every 250 Hours Service
  - Every 500 Hours Service
  - Every 1000 Hours Service
  - Every 2000 Hours Service
  - Every 4000 Hours Service
  - Every 6000 Hours Service
  - Every 8000 Hours Service
SPECIFICATIONS
- SPECIFICATIONS
OPTIONS, ATTACHMENTS
- HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL (ARAC)
  - Explanation of Components
  - Method Of Operation
- HANDLING PAYLOAD METER HM
  - Features of Payload Meter HM
  - Method of Using Accurately
  - General Locations
  - Content of Display (Controller, External Display Lamps)
  - External Display Lamps
  - Details of Data Stored in Memory of Payload Meter
  - Operation of Switches
  - Performing Calibration
  - Forced Display of Total Payload and Overall Number of Cycles
  - Method of Operation
  - Dimming Lights on Monitor Display
  - Service Check Mode
  - Abnormality and Warning Display (Error Code)
  - Procedure When Downloading
- USE OF REAR VIEW MONITOR
  - Name and Function of Each Part of Rear View Monitor
  - Setting of Rear View Monitor
  - Cautions When Using Rear View Monitor
- HANDLING DUMPING COUNTER
  - Method of Displaying, Resetting Dumping Counter
- HANDLING BATTERY DISCONNECTOR SWITCH
- HANDLING MACHINES EQUIPPED WITH KOMTRAX
  - Basic Precautions